Patents by Inventor Lanrik Wayne Kester
Lanrik Wayne Kester has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 11952285Abstract: A process of forming a sintered article includes heating a green portion of a tape of polycrystalline ceramic and/or minerals in organic binder at a binder removal zone to a temperature sufficient to pyrolyze the binder; horizontally conveying the portion of tape with organic binder removed from the binder removal zone to a sintering zone; and sintering polycrystalline ceramic and/or minerals of the portion of tape at the sintering zone, wherein the tape simultaneously extends through the removal and sintering zones.Type: GrantFiled: July 25, 2023Date of Patent: April 9, 2024Assignee: Corning IncorporatedInventors: Micheal Edward Badding, William Joseph Bouton, Douglas Edward Brackley, Lanrik Wayne Kester, Thomas Dale Ketcham, Eric Lee Miller, Cameron Wayne Tanner, James William Zimmermann
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Patent number: 11953264Abstract: A method of manufacturing ceramic tape includes a step of directing a tape of partially-sintered ceramic into a furnace. The tape is partially-sintered such that grains of the ceramic are fused to one another yet the tape still includes at least 10% porosity by volume, where the porosity refers to volume of the tape unoccupied by the ceramic. The method further includes steps of conveying the tape through the furnace and further sintering the tape as the tape is conveyed through the furnace. The porosity of the tape decreases during the further sintering step.Type: GrantFiled: August 29, 2023Date of Patent: April 9, 2024Assignee: Corning IncorporatedInventors: Michael Edward Badding, William Joseph Bouton, Jacqueline Leslie Brown, Timothy Joseph Curry, Roman E Hurny, Lanrik Wayne Kester, Thomas Dale Ketcham, John Albert Olenick, Kathleen Ritter Olenick, Jeremy Paananen, Thomas Silverblatt, Dell Joseph St Julien, Viswanathan Venkateswaran, Nathan Michael Zink
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Patent number: 11919196Abstract: A manufacturing system includes a tape advancing through the manufacturing system and a station of the manufacturing system. The tape includes a first portion having grains of an inorganic material bound by an organic binder. The station of the manufacturing system receives the first portion of the tape and prepares the tape for sintering by chemically changing the organic binder and/or removing the organic binder from the first portion of the tape, leaving the grains of the inorganic material, to form a second portion of the tape and, at least in part, prepare the tape for sintering.Type: GrantFiled: July 25, 2023Date of Patent: March 5, 2024Assignee: Corning IncorporatedInventors: Michael Edward Badding, William Joseph Bouton, Lanrik Wayne Kester, Thomas Dale Ketcham, Andrew Peter Kittleson, Dale Charles Marshall, Gary Edward Merz, Eric Lee Miller, Emmanuel Chima Okpara, Conor James Walsh
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Publication number: 20240019209Abstract: A method of manufacturing ceramic tape includes a step of directing a tape of partially-sintered ceramic into a furnace. The tape is partially-sintered such that grains of the ceramic are fused to one another yet the tape still includes at least 10% porosity by volume, where the porosity refers to volume of the tape unoccupied by the ceramic. The method further includes steps of conveying the tape through the furnace and further sintering the tape as the tape is conveyed through the furnace. The porosity of the tape decreases during the further sintering step.Type: ApplicationFiled: August 29, 2023Publication date: January 18, 2024Inventors: Michael Edward Badding, William Joseph Bouton, Jacqueline Leslie Brown, Timothy Joseph Curry, Roman E. Hurny, Lanrik Wayne Kester, Thomas Dale Ketcham, John Albert Olenick, Kathleen Ritter Olenick, Jeremy Paananen, Thomas Silverblatt, Dell Joseph St Julien, Viswanathan Venkateswaran, Nathan Michael Zink
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Publication number: 20230364828Abstract: A manufacturing system includes a tape advancing through the manufacturing system and a station of the manufacturing system. The tape includes a first portion having grains of an inorganic material bound by an organic binder. The station of the manufacturing system receives the first portion of the tape and prepares the tape for sintering by chemically changing the organic binder and/or removing the organic binder from the first portion of the tape, leaving the grains of the inorganic material, to form a second portion of the tape and, at least in part, prepare the tape for sintering.Type: ApplicationFiled: July 25, 2023Publication date: November 16, 2023Inventors: Michael Edward Badding, William Joseph Bouton, Lanrik Wayne Kester, Thomas Dale Ketcham, Andrew Peter Kittleson, Dale Charles Marshall, Gary Edward Merz, Eric Lee Miller, Emmanuel Chima Okpara, Conor James Walsh
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Publication number: 20230365423Abstract: A process of forming a sintered article includes heating a green portion of a tape of polycrystalline ceramic and/or minerals in organic binder at a binder removal zone to a temperature sufficient to pyrolyze the binder; horizontally conveying the portion of tape with organic binder removed from the binder removal zone to a sintering zone; and sintering polycrystalline ceramic and/or minerals of the portion of tape at the sintering zone, wherein the tape simultaneously extends through the removal and sintering zones.Type: ApplicationFiled: July 25, 2023Publication date: November 16, 2023Inventors: Micheal Edward Badding, William Joseph Bouton, Douglas Edward Brackley, Lanrik Wayne Kester, Thomas Dale Ketcham, Eric Lee Miller, Cameron Wayne Tanner, James William Zimmermann
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Patent number: 11768032Abstract: A method of manufacturing ceramic tape includes a step of directing a tape of partially-sintered ceramic into a furnace. The tape is partially-sintered such that grains of the ceramic are fused to one another yet the tape still includes at least 10% porosity by volume, where the porosity refers to volume of the tape unoccupied by the ceramic. The method further includes steps of conveying the tape through the furnace and further sintering the tape as the tape is conveyed through the furnace. The porosity of the tape decreases during the further sintering step.Type: GrantFiled: March 1, 2023Date of Patent: September 26, 2023Assignee: Corning IncorporatedInventors: Michael Edward Badding, William Joseph Bouton, Jacqueline Leslie Brown, Timothy Joseph Curry, Roman E Hurny, Lanrik Wayne Kester, Thomas Dale Ketcham, John Albert Olenick, Kathleen Ritter Olenick, Jeremy Paananen, Thomas Silverblatt, Dell Joseph St Julien, Viswanathan Venkateswaran, Nathan Michael Zink
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Patent number: 11745385Abstract: A manufacturing system includes a tape advancing through the manufacturing system and a station of the manufacturing system. The tape includes a first portion having grains of an inorganic material bound by an organic binder. The station of the manufacturing system receives the first portion of the tape and prepares the tape for sintering by chemically changing the organic binder and/or removing the organic binder from the first portion of the tape, leaving the grains of the inorganic material, to form a second portion of the tape and, at least in part, prepare the tape for sintering.Type: GrantFiled: January 10, 2023Date of Patent: September 5, 2023Assignee: Corning IncorporatedInventors: Michael Edward Badding, William Joseph Bouton, Lanrik Wayne Kester, Thomas Dale Ketcham, Andrew Peter Kittleson, Dale Charles Marshall, Gary Edward Merz, Eric Lee Miller, Emmanuel Chima Okpara, Conor James Walsh
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Patent number: 11746022Abstract: A process of forming a sintered article includes heating a green portion of a tape of polycrystalline ceramic and/or minerals in organic binder at a binder removal zone to a temperature sufficient to pyrolyze the binder; horizontally conveying the portion of tape with organic binder removed from the binder removal zone to a sintering zone; and sintering polycrystalline ceramic and/or minerals of the portion of tape at the sintering zone, wherein the tape simultaneously extends through the removal and sintering zones.Type: GrantFiled: November 16, 2022Date of Patent: September 5, 2023Assignee: Corning IncorporatedInventors: Michael Edward Badding, William Joseph Bouton, Douglas Edward Brackley, Lanrik Wayne Kester, Thomas Dale Ketcham, Eric Lee Miller, Cameron Wayne Tanner, James William Zimmermann
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Publication number: 20230204285Abstract: A method of manufacturing ceramic tape includes a step of directing a tape of partially-sintered ceramic into a furnace. The tape is partially-sintered such that grains of the ceramic are fused to one another yet the tape still includes at least 10% porosity by volume, where the porosity refers to volume of the tape unoccupied by the ceramic. The method further includes steps of conveying the tape through the furnace and further sintering the tape as the tape is conveyed through the furnace. The porosity of the tape decreases during the further sintering step.Type: ApplicationFiled: March 1, 2023Publication date: June 29, 2023Inventors: Michael Edward Badding, William Joseph Bouton, Jacqueline Leslie Brown, Timothy Joseph Curry, Roman E Hurny, Lanrik Wayne Kester, Thomas Dale Ketcham, John Albert Olenick, Kathleen Ritter Olenick, Jeremy Paananen, Thomas Silverblatt, Dell Joseph St Julien, Viswanathan Venkateswaran, Nathan Michael Zink
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Publication number: 20230158708Abstract: A manufacturing system includes a tape advancing through the manufacturing system and a station of the manufacturing system. The tape includes a first portion having grains of an inorganic material bound by an organic binder. The station of the manufacturing system receives the first portion of the tape and prepares the tape for sintering by chemically changing the organic binder and/or removing the organic binder from the first portion of the tape, leaving the grains of the inorganic material, to form a second portion of the tape and, at least in part, prepare the tape for sintering.Type: ApplicationFiled: January 10, 2023Publication date: May 25, 2023Inventors: Michael Edward Badding, William Joseph Bouton, Lanrik Wayne Kester, Thomas Dale Ketcham, Andrew Peter Kittleson, Dale Charles Marshall, Gary Edward Merz, Eric Lee Miller, Emmanuel Chima Okpara, Conor James Walsh
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Patent number: 11629915Abstract: A method of manufacturing ceramic tape includes a step of directing a tape of partially-sintered ceramic into a furnace. The tape is partially-sintered such that grains of the ceramic are fused to one another yet the tape still includes at least 10% porosity by volume, where the porosity refers to volume of the tape unoccupied by the ceramic. The method further includes steps of conveying the tape through the furnace and further sintering the tape as the tape is conveyed through the furnace. The porosity of the tape decreases during the further sintering step.Type: GrantFiled: September 8, 2021Date of Patent: April 18, 2023Assignee: Corning IncorporatedInventors: Michael Edward Badding, William Joseph Bouton, Jacqueline Leslie Brown, Timothy Joseph Curry, Roman E Hurny, Lanrik Wayne Kester, Thomas Dale Ketcham, John Albert Olenick, Kathleen Ritter Olenick, Jeremy Paananen, Thomas Silverblatt, Dell Joseph St Julien, Viswanathan Venkateswaran, Nathan Michael Zink
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Publication number: 20230074514Abstract: A process of forming a sintered article includes heating a green portion of a tape of polycrystalline ceramic and/or minerals in organic binder at a binder removal zone to a temperature sufficient to pyrolyze the binder; horizontally conveying the portion of tape with organic binder removed from the binder removal zone to a sintering zone; and sintering polycrystalline ceramic and/or minerals of the portion of tape at the sintering zone, wherein the tape simultaneously extends through the removal and sintering zones.Type: ApplicationFiled: November 16, 2022Publication date: March 9, 2023Inventors: Michael Edward Badding, William Joseph Bouton, Douglas Edward Brackley, Lanrik Wayne Kester, Thomas Dale Ketcham, Eric Lee Miller, Cameron Wayne Tanner, James William Zimmermann
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Patent number: 11577427Abstract: A manufacturing system includes a tape advancing through the manufacturing system and a station of the manufacturing system. The tape includes a first portion having grains of an inorganic material bound by an organic binder. The station of the manufacturing system receives the first portion of the tape and prepares the tape for sintering by chemically changing the organic binder and/or removing the organic binder from the first portion of the tape, leaving the grains of the inorganic material, to form a second portion of the tape and, at least in part, prepare the tape for sintering.Type: GrantFiled: May 6, 2022Date of Patent: February 14, 2023Assignee: Corning IncorporatedInventors: Michael Edward Badding, William Joseph Bouton, Lanrik Wayne Kester, Thomas Dale Ketcham, Andrew Peter Kittleson, Dale Charles Marshall, Gary Edward Merz, Eric Lee Miller, Emmanuel Chima Okpara, Conor James Walsh
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Patent number: 11505468Abstract: A process of forming a sintered article includes heating a green portion of a tape of polycrystalline ceramic and/or minerals in organic binder at a binder removal zone to a temperature sufficient to pyrolyze the binder; horizontally conveying the portion of tape with organic binder removed from the binder removal zone to a sintering zone; and sintering polycrystalline ceramic and/or minerals of the portion of tape at the sintering zone, wherein the tape simultaneously extends through the removal and sintering zones.Type: GrantFiled: April 12, 2022Date of Patent: November 22, 2022Assignee: CORNING INCORPORATEDInventors: Michael Edward Badding, William Joseph Bouton, Douglas Edward Brackley, Lanrik Wayne Kester, Thomas Dale Ketcham, Eric Lee Miller, Cameron Wayne Tanner, James William Zimmermann
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Patent number: 11502330Abstract: A method of forming a solid, dense, hermetic lithium-ion electrolyte membrane comprises combing an amorphous, glassy, or low melting temperature solid reactant with a refractory oxide reactant to form a mixture, casting the mixture to form a green body, and sintering the green body to form a solid membrane. The resulting electrolyte membranes can be incorporated into lithium-ion batteries.Type: GrantFiled: March 8, 2021Date of Patent: November 15, 2022Assignee: CORNING INCORPORATEDInventors: Bruce Gardiner Aitken, Michael Edward Badding, George Halsey Beall, Curtis Robert Fekety, Lanrik Wayne Kester, Robert Michael Morena, Zhen Song
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Publication number: 20220344711Abstract: Lithium-containing polycrystalline ceramic sheets include grains having an average grain size of less than 5 ?m, a relative density greater than 90%, and a thickness of up to 200 ?m. In aspects, the lithium-containing polycrystalline ceramic sheets include an outer edge of the sheet that has no height variations greater than 1 mm from baseline in a perimeter trace. In aspects, the lithium-containing polycrystalline ceramic sheets include microstructural features of an outer edge of the sheet are no greater than about ? the thickness of the sheet. In aspects, the lithium-containing polycrystalline ceramic sheets include an outer edge of the sheet that is enriched in lithium relative to a bulk of the sheet.Type: ApplicationFiled: July 11, 2022Publication date: October 27, 2022Inventors: Michael Edward Badding, Indrajit Dutta, Lanrik Wayne Kester, Xinghua Li
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Patent number: 11469446Abstract: The disclosure relates to ceramic lithium ion electrolyte membranes and processes for forming them. The ceramic lithium electrolyte membrane may comprise at least one ablative edge. Exemplary processes for forming the ceramic lithium ion electrolyte membranes comprise fabricating a lithium ion electrolyte sheet and cutting at least one edge of the fabricated electrolyte sheet with an ablative laser.Type: GrantFiled: October 22, 2020Date of Patent: October 11, 2022Assignee: Corning IncorporatedInventors: Michael Edward Badding, Indrajit Dutta, Lanrik Wayne Kester, Xinghua Li
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Publication number: 20220320576Abstract: Solid lithium-ion ceramic electrolyte membranes have an average thickness of less than 200 micrometers. A constituent electrolyte material has an average grain size of less than 10 micrometers. The solid lithium-ion ceramic electrolyte is free-standing. Alternatively, solid lithium-ion electrolyte membranes have a composition represented by Li1+x?yMxM?2?x?yM?y(PO4)3, where M is a 3+ ion, M? is a 4+ ion, M? is a 5+ ion, 0?x?2 and 0?y?2.Type: ApplicationFiled: June 20, 2022Publication date: October 6, 2022Inventors: Bruce Gardiner Aitken, Michael Edward Badding, George Halsey Beall, Curtis Robert Fekety, Lanrik Wayne Kester, Robert Michael Morena, Zhen Song
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Publication number: 20220297344Abstract: A manufacturing system includes a tape advancing through the manufacturing system and a station of the manufacturing system. The tape includes a first portion having grains of an inorganic material bound by an organic binder. The station of the manufacturing system receives the first portion of the tape and prepares the tape for sintering by chemically changing the organic binder and/or removing the organic binder from the first portion of the tape, leaving the grains of the inorganic material, to form a second portion of the tape and, at least in part, prepare the tape for sintering.Type: ApplicationFiled: May 6, 2022Publication date: September 22, 2022Inventors: Michael Edward Badding, William Joseph Bouton, Lanrik Wayne Kester, Thomas Dale Ketcham, Andrew Peter Kittleson, Dale Charles Marshall, Gary Edward Merz, Eric Lee Miller, Emmanuel Chima Okpara, Conor James Walsh